Battery Pack Assembly For Providing Structure and Support, Coolant Circulation and Electrical Connections To A Plurality of Battery Cells

Abstract

A battery pack structural and electrical assembly for circulating a coolant fluid is disclosed. The battery pack assembly includes a top cooling fluid distribution manifold attached to the top of a plurality of battery cells and a bottom cooling fluid distribution manifold that is attached to the bottom of the battery cells. A coolant fluid is circulated through the manifolds for cooling the battery cells directly. Electrical connections to the battery cells can be integrated into the manifolds for also efficiently providing electrical connections to the batteries. In addition, the battery assembly provides significant impact resistance for protecting the battery cells.

What is claimed: 
     
         1 . A battery pack structural and electrical assembly for circulating a coolant fluid comprising:
 a top cooling fluid distribution manifold comprising a top battery plate spaced from a top cover plate and defining a space therebetween for circulating a coolant fluid, the top cooling fluid distribution manifold further comprising a first conductive battery member and a second conductive battery member, the first and second conductive battery members being attached to the top cover plate, and wherein the top cooling fluid distribution manifold is configured to attach and seal against a plurality of battery cells for circulating a coolant fluid that contacts the battery cells and the first and second conductive battery members, and wherein the first conductive battery member is positioned so as to contact a positive terminal on a battery cell attached to the top cooling fluid distribution manifold, and wherein the second conductive battery member is positioned so as to contact a negative terminal on a battery cell attached to the top cooling fluid distribution manifold;   a bottom cooling fluid distribution manifold comprising a bottom battery plate spaced from a bottom cover plate and defining a space therebetween for receiving a coolant fluid, the bottom cooling fluid distribution manifold being configured to attach and seal against an opposite side of the plurality of battery cells for circulating a coolant fluid that contacts the battery cells; and   at least one fluid passageway that provides fluid communication between the top cooling fluid distribution manifold and the bottom cooling fluid distribution manifold.   
     
     
         2 . A battery pack assembly as defined in  claim 1 , further comprising a coolant fluid inlet and a coolant fluid outlet that are in fluid communication with the top cooling fluid distribution manifold and the bottom cooling fluid distribution manifold for flowing a coolant fluid through same. 
     
     
         3 . A battery pack assembly as defined in  claim 2 , wherein one of the coolant fluid inlet or coolant fluid outlet is connected to the top cooling fluid distribution manifold and wherein the other coolant fluid inlet or coolant fluid outlet is connected to the bottom cooling fluid distribution manifold and wherein the coolant fluid inlet is positioned adjacent to the coolant fluid outlet. 
     
     
         4 . A battery pack assembly as defined in  claim 1 , wherein the bottom cooling fluid distribution manifold defines a plurality of battery cell vents comprising openings in the bottom cover plate, each opening being positioned to correspond to a battery cell attached to the bottom cooling fluid distribution manifold. 
     
     
         5 . A battery pack assembly as defined in  claim 4 , wherein each battery cell vent is surrounded by a vent weld ring that is configured to be welded to a corresponding battery cell for preventing a coolant fluid circulating through the bottom cooling fluid distribution manifold from entering the battery cell vents. 
     
     
         6 . A battery pack assembly as defined in  claim 5 , wherein the bottom plate includes a plurality of perimeter weld rings, each perimeter weld ring surrounding and being spaced from a corresponding vent weld ring, each perimeter weld ring being configured to attach to a corresponding battery cell. 
     
     
         7 . A battery pack assembly as defined in  claim 1 , wherein the top cooling fluid distribution manifold defines a plurality of weld access openings, the weld access openings being positioned over the first conductive battery member and over the second conductive battery member, the weld access openings being configured to provide access to the first conductive battery member for welding the first conductive battery member to corresponding positive terminals on battery cells attached to the top cooling fluid distribution manifold and being configured to provide access to the second conductive battery member for welding the second conductive battery member to corresponding negative terminals on battery cells attached to the top cooling fluid distribution manifold. 
     
     
         8 . A battery pack assembly as defined in  claim 1 , wherein the top cooling fluid distribution manifold includes a positive terminal in electrical communication with the first conductive battery member and a negative terminal in communication with the second conductive battery member. 
     
     
         9 . A battery pack assembly as defined in  claim 1 , wherein the top battery plate of the top cooling fluid distribution manifold defines a plurality of battery cell openings for mating with a corresponding plurality of battery cells, each battery cell opening being surrounded by a top perimeter weld ring for welding to a corresponding battery cell. 
     
     
         10 . A battery pack assembly as defined in  claim 1 , wherein the top battery plate and the top cover plate of the top cooling fluid distribution manifold and the bottom cooling fluid distribution manifold are comprised of a polymer. 
     
     
         11 . A battery pack assembly as defined in  claim 10 , wherein the polymer comprises a thermoplastic resin containing reinforcing fibers. 
     
     
         12 . A battery pack assembly as defined in  claim 10 , wherein the polymer comprises a polyamide, a polyolefin, a polyester, a copolyether ester, a polyphenylene sulfide, a polyoxymethylene, or a liquid crystal polymer. 
     
     
         13 . A battery pack assembly as defined in  claim 10 , wherein the top battery plate, the top cover plate, and the bottom cooling fluid distribution manifold are injection molded. 
     
     
         14 . A battery pack assembly as defined in  claim 1 , wherein the first conductive battery member and the second conductive battery member comprise a conductive metal. 
     
     
         15 . A battery pack comprising a battery pack structural and electrical assembly as defined in  claim 1  and a plurality of battery cells mounted and electrically interconnected between the top cooling fluid distribution manifold and the bottom cooling fluid distribution manifold. 
     
     
         16 . A battery pack as defined in  claim 15 , wherein each of the battery cells has a cylindrical shape. 
     
     
         17 . A battery pack as defined in  claim 15 , wherein each battery cell includes a top positioned adjacent to the top cooling fluid distribution manifold and a bottom positioned adjacent to the bottom cooling fluid distribution manifold and wherein each battery cell is welded at the top to the top cooling fluid distribution manifold and is welded at the bottom to the bottom cooling fluid distribution manifold. 
     
     
         18 . A battery pack as defined in  claim 17 , wherein each battery cell is laser welded to at least one of the distribution manifolds. 
     
     
         19 . A battery pack as defined in  claim 17 , wherein each battery cell is ultrasonically welded to at least one of the distribution manifolds. 
     
     
         20 . A battery pack as defined in  claim 15 , wherein the first conductive battery member and the second conductive battery member comprise conductive metals. 
     
     
         21 . A battery pack as defined in  claim 15 , wherein the battery pack further comprises a coolant fluid that circulates through the top cooling fluid distribution manifold and through the bottom cooling fluid distribution manifold, the coolant fluid comprising a dielectric oil, a fluorinated oil, a mineral oil, or a glycol. 
     
     
         22 . A battery pack as defined in  claim 15 , wherein the battery pack includes at least ten battery cells.